Tape cutting-out equipment and tape production supporting apparatus

ABSTRACT

Tape cutting-out equipment to wind and cut out tape supplied from a pancake in plural kinds of winding lengths on a reel, the equipment is equipped with a tape supplying device supplying tape from the pancake P, a tape winding device winding the supplied tape from the tape supplying device, a memory unit memorizing position data of defect portions of the tape in the pancake, a winding length deciding unit deciding a winding length of the tape based on the position data read out from the memory unit, a cutting device cutting the tape, and a cutting control unit controlling making the cutting device cut the tape at a timing when the tape winding device winds tape of the winding length decided by the winding length deciding unit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of application Ser. No. 10/687,609 filed Oct. 20,2003. The entire disclosure of the prior application, application Ser.No. 10/687,609 is hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to tape cutting-out equipment and a tapeproduction supporting apparatus so as to lessen a waste portion.

BACKGROUND OF THE INVENTION

Generally, in a manufacturing process of a magnetic tape, it is knownthat defects occur in the magnetic tape due to magnetic liquid of astate mixed with foreign matters such as dust being coated on asupporting body (base tape), not being locally coated because of defectsof the supporting body itself, and the like.

Moreover, in a magnetic tape for high-density recording, a servo signalis written by a servo writer and defects also occur in the magnetic tapedue to a writing error of the servo signal.

In a portion with such the defects, because data cannot berecorded/reproduced, a magnetic tape including a defect portion needs tobe eliminated.

For an eliminating method, there is a following one.

There exists a method that a magnetic tape wound in a pancake, after aservo signal being written by a servo writer, is wound by a windingdevice on a product reel, so when errors exist inspecting a servo signalwriting error of the magnetic tape in winding by the winding device,products together with a reel is scrapped as a product reel with defectportions.

On the other hand, there exists another method that memorizing positionswith defects in a pancake in advance, when there exists no defect withina predetermined length in winding on a reel, wind the length as it is,and when there exists a defect, control to wind tape till a portion withthe defect on a reject reel and scrap a magnetic tape wound on thereject reel (for example, see pages 3 and 4, and FIG. 1 in Japan patentlaid open publication 7-37362).

However, there exists a problem that to scrap tape having defects in apart together with a reel on which hundreds of meters of the tape withthe defects in a part are wound results in scrapping a portion of amagnetic tape which can be effectively utilized and there is aconsiderably large amount of waste.

When a production plan is such a one to cut out a single length of tapefrom a pancake, the above waste is inevitable, however when cutting outdifferent lengths of tape, there should exist a combination of acutting-out method with less waste.

SUMMARY OF THE INVENTION

The present invention is embodied considering the above mentionedproblem, and an exemplary object of the invention is to provide tapecutting-out equipment and a tape production supporting apparatus whichcan lessen a waste portion with eliminating a defect portion of amagnetic tape.

The invention is composed to solve the problem, and firstly, tapecutting-out equipment of the invention is equipment which winds and cutsout tape supplied from a pancake at plural kinds of lengths and ischaracterized by being equipped with a tape supplying device supplyingtape from a pancake, a tape winding device winding the tape suppliedfrom the pancake on a reel, a memory unit memorizing position data oftape defect portions in the pancake, a winding length deciding unitdeciding a tape winding length based on position data read from thememory unit, a cutting device cutting the tape, and a cutting controlunit making the cutting device cut the tape when the tape winding devicehas wound a decided winding length of tape decided by the winding lengthdeciding unit.

The tape cutting-out equipment of the invention enables a waste portionto be lessened by cutting out the tape with eliminating the tape defectportions because the winding length deciding unit decides a cuttinglength of the tape based on the position data of the tape defectportions.

In addition, in the tape cutting-out equipment, the winding lengthdeciding unit can also be composed so as to determine based on theposition data read from the memory unit whether or not a defect portionexists within one kind of winding length: when it is judged that nodefect portion exists, the one kind of winding length is decided as awinding length next wound; and when judged that a defect portion exists,a winding length is decided by determining whether or not a defectportion exists within a shorter other kind of winding length.

Moreover, in the tape cutting-out equipment, the winding length decidingunit can also be composed so as to calculate combinations of windinglengths by which tape can be wound without including a defect portionand with the least waste from one pancake, based on the position dataread from the memory unit, and to decide a winding length.

Thus, the winding length deciding unit can calculate the combinations ofthe winding lengths by which tape can be wound with the least waste.Therefore, tape can be cut with a combination of winding lengthsrestraining waste minimum.

Next, a tape production supporting apparatus of the invention is theapparatus which cuts out tape from a pancake without waste and ischaracterized by having an input unit setting plural kinds of windinglengths scheduled to be produced in a production plan of the day, amemory unit memorizing position data of defect portions of tape in apancake, a computing unit calculating combinations of winding lengths bywhich tape can be wound with the least waste and without including adefect portion from one pancake based on position data read from thememory unit, a ratio computing unit obtaining a ratio of tape which isusable from the pancake based on the combinations of the winding lengthscalculated by the computing unit, and an output unit outputtingjudgement results of the ratio computing unit.

According to the tape production supporting apparatus of the invention,the computing unit calculates the combinations of the winding lengthswhich can be wound without including a defect portion and with the leastwaste from plural kinds of winding lengths matching the production planof the day and the ratio computing unit obtains the ratio of the tapewhich is usable from the pancake based on the combinations of thewinding lengths. Then, the output unit outputs the judgement results, sowhen a manager watches the results and judges that many waste portionsexist in case of using the pancake in production of the day, the pancakecan be arranged for production in a later day, whereby an effectiveutilization of the tape can be achieved.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram showing a configuration of tape cutting-outequipment related to a first embodiment of the invention.

FIG. 2 is a flowchart illustrating a procedure by which a winding lengthdeciding unit decides a winding length.

FIG. 3 is a drawing of a magnetic tape illustrating a method todetermine a winding length.

FIG. 4 is a drawing showing a configuration of a tape productionsupporting apparatus related to a second embodiment of the invention.

FIG. 5 is a flowchart illustrating an operation procedure of a tapeproduction supporting apparatus.

FIG. 6 is a drawing of a magnetic tape illustrating a method todetermine a winding length.

DESCRIPTION OF THE PREFERRED EMBODIMENTS a. First Embodiment

Hereinafter, a first embodiment of the present invention will bedescribed in detail, referring to drawings as needed. Meanwhile, it isassumed that a magnetic tape is applied to the first embodiment.

As shown in FIG. 1, the tape cutting-out equipment 1 related to thefirst embodiment is composed of a tape supplying device 10 supplying amagnetic tape MT from a pancake P, a tape winding device 20 winding thesupplied magnetic tape MT, a memory unit 30 memorizing position data ofdefect portions of the magnetic tape MT in the pancake P, a windinglength deciding unit 40 deciding a winding length of the magnetic tapeMT, a cutting device 50 disposed between the tape supplying device 10and tape winding device 20, and a cutting control unit 60 controllingthe cutting device 50.

The tape supplying device 10 in which the pancake P wound on a reel R1is inserted is the device to supply the tape winding device 20 with themagnetic tape MT from the pancake P. The reel R1 is rotated by a motornot shown in the drawing at a predetermined rotation number and sendsout the magnetic tape MT wound on a circumference at a predeterminedspeed toward the tape winding device 20.

The tape winding device 20 is the device to wind the magnetic tape MTsupplied from the tape supplying device 10 on a reel R2. The reel R2 ofthe winding device 20 is rotated by a motor not shown in the drawing ata predetermined rotation number and winds the magnetic tape MT at apredetermined speed on its circumference. Meanwhile, plural guiderollers G are provided between the supplying device 10 and windingdevice 20, and being guided by the guide rollers G, the tape MT is woundon the winding device 20

The memory unit 30 memorizes the position data of defect portions of themagnetic tape MT in the pancake P.

In the magnetic tape MT supplied from the pancake P, before the pancakeP is inserted in the tape supplying device 10, servo signals are writtenin advance by a servo writer not shown in the drawing and presence orabsence of defects of servo signals is judged by an inspection device Sequipped with the servo writer. In each pancake, making correspondencebetween a number specifying a pancake and defect positions in it, theyare recorded in a barcode label BC and the like appended to a top endportion of the tape MT. Then, the cutting-out equipment 1 memorizes apancake number and defect positions read from the barcode label BC inthe memory unit 30. Meanwhile, although, as defects of the tape MT,those of the servo signals are exemplified here, the defects are notlimited to those of the servo signals and the present invention issimilarly applicable to other nonconformities such as a pin hole due topeeling-off of a magnetic layer, surface accuracy, and width orlinearity of the tape MT.

The winding length deciding unit 40 decides, based on the position dataof defect portions in the pancake P, a winding length of the tape MTfrom plural kinds of winding lengths so as to effectively utilize thetape MT as much as possible. For example, if a defect portion isincluded in a firstly set winding length, judge whether it is possibleto wind a shorter winding length than the set length without includingdefects and decide the winding length. Meanwhile, plural kinds ofwinding lengths, for example, assuming a length defined by aspecification of each kind of product, are set in different channels,respectively.

The cutting device 50 has a cutter 51 and it cuts the tape MT.

Meanwhile, the cutting control unit 60 makes the cutting device 50 cutthe tape MT when the tape winding device 20 has wound a winding lengthof the tape MT decided by the winding length deciding unit 40.

Next, referring to FIGS. 2 and 3, operation of the cutting-out equipment1 related to the first embodiment is described.

Firstly, insert a pancake P of which position data of defect portionsmemorized in the memory unit 30 in the tape supplying device 10. Then,by reading a barcode BC appended to the pancake P, can specify thepancake P and read the position data of defect portions of the pancake.

For the pancake P inserted in the supplying device 10, the windinglength deciding unit 40 decides a winding length from a winding startend A of the tape MT shown in FIG. 3, changing channels, out of pluralkinds of winding lengths. Here, for the plural kinds of winding lengths,500, 400, 300, 200, and 100 m are assumed to exist and 500 m is assumedto be set in advance as a basic winding length.

Operation of the winding length deciding unit 40 is described referringto FIG. 2.

Firstly, in an S1, judge from the winding start end A whether or not adefect portion exists in a winding length of 500 m set in advance. Inthe S1, if no defect exists in the set winding length of 500 m (No),proceed to an S2 and decide to wind the set winding length (500 m).Then, if defects exist in the set winding length of 500 m (Yes), proceedto an S3 and judge with eliminating defect portions whether to be ableto wind remained portions for a shorter-length product. In the S3, incase of judging to be able to wind the remained portions for ashorter-length product (Yes), for example, in case of being able to wind300 m, proceed to an S5 and decide to wind the remained portions in 300m. Meanwhile, in the S3, judge whether to be able to wind the remainedportions for a shorter-length product till a shortest winding length, soin case of being unable to even wind 300 m, sequentially judge whetherto be able to wind 200 m and 100 m. For example, in order not to includea defect portion in a portion starting from a position C in FIG. 3,although 300 and 200 m cannot be wound, 100 m can be wound, therebydecision of winding in 100 m being represented.

In the S3, in case of judging to be unable to wind the remained portionsfor a shorter-length product (No), that is, in case of including adefect portion in the shortest winding length (100 m) from the nextwinding start end (D to E in FIG. 3), proceed to an S4 and wind theremained portions on a reject reel and the like so as to include thedefect portion.

Then, in the S2, S4, or S5, if a winding length is decided, again repeatthe same procedures to decide a next winding length from a finish endportion of its winding length.

Below, referring to FIG. 3, one example of a method for deciding awinding length of a pancake P is described.

Because a first winding (A to B) does not include any defect portionwithin 500 m from the winding start end A, decide to wind 500 m.Although a second winding (B to C) includes a defect portion within 500m from a winding start end B, it does not include any defect portionwithin 300 m, thereby winding it in 300 m being decided. Although athird winding (C to D) includes a defect portion within 500, 300, and200 m from a winding start end C, it does not include any defect portionwithin 100 m, thereby winding it in 100 m being decided. Because a nextwinding (D to E) includes a defect portion within 100 m of the shortestwinding length, decide to wind it till the position so as to include thedefect portion. Moreover, according to a flowchart shown in FIG. 2,repeat the same procedures.

Thus, in the tape cutting-out equipment of the first embodiment,following effects can be obtained.

Because the winding length deciding unit 40 decides a cutting length ofthe magnetic tape MT based on position data of its defect portions, thetape MT is cut out at an effectively utilized length with eliminatingthe defect portions, thereby a waste portion being able to be lessened.

Although, as described above, the first embodiment is described, thepresent invention can be practiced in a following embodiment.

For example, in the embodiment, although the decision method of awinding length is decided so as not to include a defect portion byjudging whether to be able to be wound for a shorter winding lengthproduct, it is also possible to decide a winding length based onposition data of defect portions by calculating combinations of windinglengths which can wind tape without including a defect portion and withthe least waste from one pancake. Thus, a waste magnetic tape can bemade less.

b. Second Embodiment

Next, a second embodiment related to the tape production supportingapparatus will be described referring to FIGS. 4 to 6.

As shown in FIG. 4, the tape production supporting apparatus 2 iscomposed of an input unit 71, a memory unit 72, a computing unit 73, aratio computing unit 74, and an output unit 75. These can be controlledby one PC.

Firstly, the input unit 71 can set plural kinds of winding lengthsscheduled to be produced in a production plan of the day. Here, 500,300, and 200 m are winding lengths scheduled to be produced on the day.

Then, the memory unit 72 memorizes position data of defect portions of amagnetic tape in one pancake P. A memorizing method similar to that ofthe memory unit 30 described before is based on the barcode label BC.

The computing unit 73 calculates combinations of winding lengths whichcan be wound with the least waste, eliminating defect portions, based onthe position data of defect portions of the magnetic tape in the memoryunit 72 and plural kinds of winding lengths input from the input unit71.

Moreover, the ratio computing unit 74 obtains a ratio of the magnetictape usable from the pancake P based on the combinations of the windinglengths calculated by the computing unit 73, and if the ratio is equalor more than a predetermined value, it decides to use the pancake P;whereas if the ratio is less than the predetermined value, it decidesnot to use the pancake P on the day. Meanwhile, for the usability ornot, make the memory unit 72 memorize as usable or not usableinformation of the pancake P, and then, even when an operator and thelike inserts the pancake P in the tape cutting-out equipment by mistake,it is preferable for the cutting-out equipment to be able to control notto cut out it.

The output unit 75 displays judgement results of the ratio computingunit 74.

Next, referring to FIG. 5, operation procedures of the tape productionsupporting apparatus 2 are described.

Firstly, in an S11, calculate combinations with the least waste incombinations of winding lengths produced on the day based on informationof the barcode label BC of one pancake P. For example, calculate allcombinations of winding lengths which become equal or less than a tapelength from a defect to defect, compare among windable lengths in eachcombination calculated, and select a combination windable longest. To bemore precise, as shown in FIG. 6, if a distance between two defectportions is 410 m, in a combination of 500, 300, and 200 m, plural kindscan be assumed such as a combination of two pieces of 200 m and a wasteportion of 10 m, another combination of one piece of 300 m and a wasteportion of 110 m, and the like. In this case, a combination which canmost effectively utilize the magnetic tape is the combination of twopieces of 200 m (a waste portion, 10 m), so in the S11, the combinationis calculated.

In an S12, calculate a ratio of the magnetic tape usable from thepancake P in the combination calculated in the S11. Then, in an S13, ifthe ratio is less than a predetermined value (No), proceed to an S14 andrecord (make marking) usable or not usable information in the memoryunit 72 so as to be unable to use the pancake P. In addition, in theS13, if the ratio is equal or more than the predetermined value (Yes),proceed to an S15 and record so as to use the pancake P. Meanwhile,without recording the usable or not usable information, output on ascreen whether usable or not and also allow an operator seeing it tofinally decide whether usable or not.

Thus, following effects can be obtained.

From plural kinds of winding lengths matching a production plan of theday, the computing unit 73 calculates a combination of winding lengthswhich can wind tape without including defect portions and with the leastwaste. Then, the ratio computing unit 74 obtains a ratio of the tapewhich is usable from the pancake P based on the combinations of thewinding lengths and if the ratio is equal or more than a predeterminedvalue, the ratio computing unit 74 decides to use the pancake P; whereasif the ratio is less than the predetermined value, the ratio computingunit 74 decides not to use the pancake P on the day. The judgementresults are displayed by the output unit 75, so in production of theday, the pancake P may be used or not, whereby effective utilization ofa magnetic tape can be achieved.

Meanwhile, the predetermined value can be easily changed in design bymaking a manager and the like be able to change the value as needed.

Thus, although the embodiments are described, the invention is notlimited to these and these are changeable in design as needed as far asthese do not deviate from the ideas of the invention.

For example, in the embodiments, although the ratio computing unit 74decides to use the pancake P in case of the ratio being equal or morethan the predetermined value, a ratio computing unit only calculates aratio and makes an output unit display it, thereby also being able tomake a manager and the like judge whether or not to use the pancake P.Thus, an optimal judgement can be made as appropriate.

Moreover, in the embodiments, although a magnetic tape is used, anoptical recording tape is also available.

1. Tape cutting-out equipment to wind and cut out tape supplied from apancake in plural kinds of winding lengths on a reel, the equipmentcomprising: a tape supplying device that supplies a tape from a pancaketo a tape winding device that winds the supplied tape; a memory unitthat memorizes position data of defect portions of the tape in saidpancake; a winding length deciding unit that decides a winding length ofsaid tape based on the position data read out from said memory unit,wherein when said winding length deciding unit determines that no defectexists in said winding length, said winding length deciding unitdetermines that said winding length is the winding length to be wound bysaid tape winding device, and when said winding length deciding unitdetermines that a defect portion does exist in said winding length, saidwinding length deciding unit determines the winding length to be woundby said tape winding device by determining whether or not said defectexists in a shorter winding length than said winding length; a cuttingdevice that cuts said tape; and a cutting control unit which controlssaid cutting device to cut said tape when said tape winding device windssaid tape said winding length, which was decided by said winding lengthdeciding unit.
 2. The tape cutting-out equipment according to claim 1,wherein when said winding length deciding unit determines that no defectexists in a plurality of winding lengths, said winding length decidingunit determines that a longest winding length of said winding lengths isthe winding length to be wound; and wherein when said winding lengthdeciding unit determines that no defect exists in said winding lengths,said winding length deciding unit determines a next plurality of windinglengths by determining whether or not another defect exists in said nextplurality of said winding lengths.
 3. The tape cutting-out equipmentaccording to claim 1, wherein said winding length deciding unitcalculates combinations of winding lengths in which said tape can bewound without including any defect portions and with the least waste ofsaid tape from said pancake based on position data read from said memoryunit.
 4. The tape cutting-out equipment according to claim 3, whereinsaid winding length deciding unit calculates a plurality of combinationsof winding lengths which are equal to or less than a length from a firstdefect to a second defect, compares said winding lengths in eachcombination calculated, and selects the longest winding lengthcombination.
 5. A tape production supporting apparatus to cut out tapefrom a pancake, the apparatus comprising: an input unit used in settinga plurality of winding lengths scheduled to be produced in a productionplan of a current day; a memory unit which memorizes position data ofdefect portions of a tape in a pancake; a computing unit whichcalculates combinations of winding lengths which can be wound withoutincluding the defect portions and with a least amount of waste, saidcombination calculations being based on the position data read from saidmemory unit and the plurality of winding lengths; a ratio computing unitwhich obtains a ratio of usable tape from said pancake based on thecombinations of the winding lengths calculated by said computing unit;and an output unit which outputs judgment results of said ratiocomputing unit.
 6. The tape cutting-out equipment according to claim 1,wherein said tape is a magnetic tape.
 7. The tape cutting-out equipmentaccording to claim 2, wherein said tape is a magnetic tape.
 8. The tapecutting-out equipment according to claim 3, wherein said tape is amagnetic tape.
 9. The tape cutting-out equipment according to claim 4,wherein said tape is a magnetic tape.
 10. The tape cutting-out equipmentaccording to claim 5, wherein said tape is a magnetic tape.
 11. The tapecutting-out equipment according to claim 1, wherein said tape is anoptical recording tape.
 12. The tape cutting-out equipment according toclaim 2, wherein said tape is an optical recording tape.
 13. The tapecutting-out equipment according to claim 3, wherein said tape is anoptical recording tape.
 14. The tape cutting-out equipment according toclaim 4, wherein said tape is an optical recording tape.
 15. The tapecutting-out equipment according to claim 5, wherein said tape is anoptical recording tape.
 16. A tape production supporting apparatus tocut out tape from a pancake, the apparatus comprising: an input unitused in setting a plurality of winding lengths scheduled to be producedin a production plan of a current day; a memory unit which memorizesposition data of defect portions of a tape in a pancake; a computingunit which calculates combinations of winding lengths which can be woundwithout including the defect portions, said combination calculationsbeing based on the position data read from said memory unit and theplurality of winding lengths; a ratio computing unit which obtains aratio of usable tape from said pancake based on the combinations of thewinding lengths calculated by said computing unit; and an output unitwhich outputs judgment results of said ratio computing unit.